Tsudakoma ZAX- Settings for standard Denim

Tsudakoma-ZAX Loom Settings for 14.5 Oz/Sq yd OE/OE Denim (EPI x PPI = 64 x 37) count (6s x 7s)


Back Rest- 125 mm (vertical)
-16th mark ( horizontal)

Dropper Box- 100 mm (vertical)
- 50 mm (vertical)

Shedding Amount

1st Frame- 99 mm
2nd Frame-91mm
3rd Frame- 83 mm
4th Frame- 75 mm

Heald Frame Height:

1st Frame - 43 mm
2nd Frame-41mm
3rd Frame-39mm
4th Frame- 37mm

Shed Crossing Timing- 290 deg

Leno Crossing Timing- 290 deg ( LH Side), 0 deg ( RH side)

Temple- 15 rings- Medium Type

Sub Nozzle angle- 4 deg
Sub nozzle height- 3rd Mark
Machine Pulley- 220 mm
Motor Pulley- 113 mm for 760 rpm

iboard Settings

Tension- 280 kgf
Upper Limit- 560 kgf
Lower Limit- 0 kgf
Pick Density- 37 pick
Turns/Pick- 4
Arrvial setting - 240 deg
Filling insertion timing- 80 deg
No. of Sub groups- 5

Timing

Feeler H1- 200 deg to 290 deg
H2- 200 deg to 310 deg
Forward- 350 deg
Rev (others)- 180 deg/320 d eg
(Filling)- 290 deg
WBS- 240deg-300deg

SENSOR/TROUBLE
Dropper Setting: 10 th Volume
Sensor- on
Feeler-on
Timing

Pin: 50deg-200 deg
Main: 50deg-200deg
AUX Main: 60deg-100deg
80deg

Auxiliary Nozzle- 76 deg-176 deg
1st Pick- 86 deg

Sub Nozzle

64deg-170 deg
100deg-190deg
130deg-220deg
150deg-230deg
170deg-250deg

Stretch Nozzle- 200deg-300deg

STOP MARK Data

1. F Kick ( Filling) - 0 upto 7 steps
2. F Kick (Others)- 0 upto 7 steps
3. R Kick ( Filling)- 0 upto 7 steps
4. R Kick (Others) - 0 upto 7 steps
5. Kick Back Speed- 1. Low 2, Medium 3, High On
6. Kickback order- on 1

1. Rev to Forward
2. Forward to Rev

7. Down time- 5 min
8. Fell Control-8
9. Dia Comp-48
10. Let Off Avg-2
11. F-Gain-0
12. R.Gain- 0

13. Gain -1
1. Low
2. Medium
3. High

14. Rush Torque- 1200%
15. change Picks-2
16. Change timing- 30 deg
17. 1 pick insertion- On
18. Autolevelling- On

Critical Process Parameters- Denim Manufacturing

Critical Process Parameters- Denim Manufacturing

Warping:

Machine Speed m/min= 600+-50
Tension on individual thread ( cN) 90+-30
Warping breaks ( Avg/10000m/400 ends) < = 0.2

Dyeing-cum-Sizing

1. Machine Speed = 30+-2
2. Size Viscosity ( Flow seconds) = 6+-1
3. Size Add on ( %)= 6+-2
4. Breaking Force (gf) sized yarn = >=1100
5. Tenacity ( cN/tex) ( sized yarn) = >13
6. Elongation ( %) of sized yarn >= 4.5

Finishing

Quality	7 x 6	7 x 6	7 x 7	7 x 9	7 x 6
Width(cm)	151+-1	149+-1	151+-1	151+-1	151+-1
Shrinkage ( %)	15+-1	14.5+-1	15.5+-1	16+-1	14+-1
Skew ( %)	5-11	5-11	5-11	5-11	5-11

Finished Properties of some Common Denim Fabrics

Finished Properties of Common Denim Fabrics: Understanding Weight, Yarn Count, Construction and Fastness

Denim is one of the most widely used fabrics in garments, especially for jeans, jackets, skirts, children’s wear and casual apparel. Although denim is often identified by its appearance, shade and wash effect, the real performance of denim depends on measurable fabric properties such as weight, yarn count, ends per inch, picks per inch, rubbing fastness and laundering fastness.

The original note listed finished properties for three common denim fabrics with ideal weights of 14.5 oz/sq yd, 13.75 oz/sq yd and 12.5 oz/sq yd. These values are useful because denim is often commercially discussed by weight category, but weight alone does not tell the full story. A merchandiser, fabric buyer or production person must also understand the relation between yarn count, fabric construction and finished performance.

Table of Contents

• Why Finished Denim Properties Matter
• Comparative Finished Properties of Common Denim Fabrics
• Understanding Fabric Weight in Denim
• Role of Warp and Weft Count
• EPI and PPI: Fabric Construction
• Rubbing Fastness and Laundering Fastness
• Practical Notes for Merchandisers
• Common Mistakes in Reading Denim Specifications
• Conclusion

Why Finished Denim Properties Matter

In denim manufacturing, the fabric that comes out of weaving is not the same as the fabric finally used in garments. Denim passes through finishing operations such as singeing, desizing, washing, sanforizing, softening, skew correction and sometimes special chemical or mechanical treatments. These processes change the fabric’s handle, dimensions, shrinkage, shade appearance and apparent fabric weight.

Therefore, when we say that a denim fabric is 14.5 oz, 13.75 oz or 12.5 oz, we should be clear whether we are talking about greige weight, finished weight or washed weight. Finished properties are especially important because the garment buyer and consumer experience the fabric after finishing, not at the loom stage.

Visual 1: Denim fabric properties map showing how weight, count, construction and fastness affect final performance.

Comparative Finished Properties of Common Denim Fabrics

Property	Heavy Denim	Medium-Heavy Denim	Medium Denim
Ideal Weight	14.5 oz/sq yd	13.75 oz/sq yd	12.5 oz/sq yd
Warp Count, Washed	6.9 ± 0.6	6.9 ± 0.5	6.9 ± 0.5
Weft Count, Washed	6.0 ± 0.4	6.9 ± 0.5	9.0 ± 0.5
EPI, Unwashed	70 ± 2	70 ± 2	70 ± 2
PPI, Unwashed	43 ± 2	43 ± 2	43 ± 2
Actual Weight	14.2 oz/sq yd	13.4 oz/sq yd	12.2 oz/sq yd
Rubbing Fastness, Dry	2–3	2–3	2–3
Fastness to Laundering	2	2	2

This small table contains an important technical lesson. The three fabrics have almost the same warp count, EPI and PPI, but the weft count changes. This means that the weight difference is mainly controlled through the weft yarn, while the face character of the fabric is kept broadly similar.

Understanding Fabric Weight in Denim

Fabric weight in denim is commonly expressed in ounces per square yard. Heavier denim generally feels thicker, stronger and more rigid, while lighter denim feels softer, more flexible and easier to wear in warm conditions. A 14.5 oz denim is usually perceived as a heavy and rugged fabric, while a 12.5 oz denim is closer to a medium-weight commercial denim.

Denim Weight	Practical Meaning	Typical Use
Around 14.5 oz	Heavy denim	Rugged jeans, workwear-inspired garments, structured bottoms
Around 13.75 oz	Medium-heavy denim	Regular jeans, casual bottoms, durable apparel
Around 12.5 oz	Medium denim	Comfortable jeans, fashion denim, lighter casual wear

In the data, the actual finished weights are slightly lower than the ideal weights. For example, the 14.5 oz fabric shows an actual weight of 14.2 oz/sq yd, while the 12.5 oz fabric shows 12.2 oz/sq yd. Such differences can occur because of yarn variation, weaving tension, finishing loss, moisture content and process conditions.

Role of Warp and Weft Count

The warp yarn count remains nearly the same in all three fabrics, around 6.9 Ne. This suggests that the main difference between the three denim qualities is not coming from the warp yarn, but from the weft yarn. The weft count changes from 6.0 Ne in the heavier fabric to 9.0 Ne in the lighter fabric.

In the English cotton count system, a lower count number means a coarser yarn. Therefore, 6s weft is coarser than 9s weft. This explains the weight difference clearly:

\( \text{Coarser weft yarn} \Rightarrow \text{more yarn mass per unit area} \Rightarrow \text{heavier denim} \)

\( \text{Finer weft yarn} \Rightarrow \text{less yarn mass per unit area} \Rightarrow \text{lighter denim} \)

This is a useful point for merchandisers. If EPI and PPI remain almost constant, but fabric weight changes, the change is often due to yarn count, especially weft count.

Visual 2: Relationship between weft count and denim weight, showing why coarser weft gives heavier fabric.

EPI and PPI: Fabric Construction

The construction shown in all three fabrics is approximately 70 × 43. This means that the fabric has about 70 ends per inch in the warp direction and about 43 picks per inch in the weft direction. Since EPI and PPI are the same across all three fabrics, the construction density remains largely unchanged.

EPI stands for ends per inch, or the number of warp yarns in one inch of fabric width. PPI stands for picks per inch, or the number of weft yarns in one inch of fabric length. In the given case:

\( \text{EPI} = 70 \pm 2 \)

\( \text{PPI} = 43 \pm 2 \)

This is a good example of how fabric properties should be read together. Looking only at fabric weight may not explain the reason for the difference. Looking at weight, yarn count and construction together gives a much clearer technical understanding.

Why Warp Count is Similar but Weft Count Changes

In conventional denim, the warp yarn is usually indigo dyed, while the weft yarn is generally undyed or lightly coloured. The warp gives denim its characteristic blue appearance, while the weft contributes strongly to weight, handle and body.

Keeping the warp count similar helps maintain a consistent denim appearance and surface character. Changing the weft count allows the manufacturer to create different weights without drastically changing the face appearance of the fabric. This is why three fabrics can look similar at first glance but behave differently in hand feel, stiffness and garment comfort.

Rubbing Fastness and Laundering Fastness

The dry rubbing fastness given for all three fabrics is 2–3. This indicates that colour transfer during rubbing is a concern. In denim, this is especially important because indigo dye is mainly present on the surface of the yarn rather than deeply penetrating the fibre.

A dry rubbing fastness rating of 2–3 means that some colour transfer may occur when the fabric rubs against another surface. This may appear as blue staining on light-coloured shirts, shoes, bags, upholstery or inner pocketing. For the merchandiser, this means care instructions and buyer expectations should be handled carefully.

The laundering fastness is shown as 2 for all three fabrics. This means that the fabric is likely to lose shade during washing. In denim, this is not always considered a defect because fading is often part of the desired denim character. However, from a quality-control perspective, this rating must be interpreted according to the buyer’s requirement.

Visual 3: Denim fastness performance map showing rubbing fastness, laundering fastness and consumer risk points.

Relationship Between Weight, Comfort and Durability

Heavier denim usually gives better body and ruggedness, but it may feel stiff and warm. Lighter denim gives better comfort and flexibility, but may not have the same rugged appeal. Medium-weight denim often becomes the commercial balance between durability and wearability.

Fabric Weight	Advantages	Possible Limitations
Heavy denim	Strong body, rugged look, durable feel	Stiffer, warmer, slower to break in
Medium-heavy denim	Good balance of strength and comfort	May still feel firm before washing
Medium denim	Softer, easier to wear, better drape	Less rugged appearance than heavy denim

Simple Weight Calculation Concept

A simplified fabric weight relationship can be understood as:

\( \text{Fabric Weight} \propto \text{Yarn Linear Density} \times \text{Fabric Density} \)

In practical terms:

\( \text{Weight} \approx f(\text{Warp Count}, \text{Weft Count}, \text{EPI}, \text{PPI}, \text{Crimp}, \text{Finishing}) \)

This means that the final denim weight is influenced by both yarn size and construction. In the present example, because EPI and PPI are constant, the difference in weight is largely explained by the difference in weft count.

Practical Notes for Merchandisers

A merchandiser should not approve denim only by looking at the weight. Two denim fabrics with the same weight can behave differently if the yarn count, twist, fibre quality, weave compactness, finishing route or shrinkage control is different.

Checkpoint	Why It Matters
Finished weight	Determines body, feel and product category
Warp and weft count	Explains yarn thickness and fabric mass
EPI and PPI	Indicates fabric density and construction stability
Rubbing fastness	Shows risk of colour transfer
Laundering fastness	Shows expected wash-down behaviour
Shrinkage	Critical for garment fit
Skew and bow	Important for leg twisting in jeans
Handle and stiffness	Affects consumer comfort
Shade consistency	Critical for bulk approval

Common Mistakes in Reading Denim Specifications

One common mistake is to assume that heavier denim is always better. This is not true. Heavy denim may be unsuitable for hot climates, fashion silhouettes or comfort products. Another mistake is to compare denim fabrics only by ounce weight without checking construction.

A third mistake is ignoring rubbing fastness. Denim may pass visual inspection but still create complaints if it stains other garments or accessories. Similarly, laundering fastness must be understood according to the intended wash effect. In denim, fading can be either a defect or a design feature, depending on the product brief.

Buyer’s Interpretation of the Given Data

The data suggests that the three denim fabrics are constructed with a similar warp system and similar fabric density. The main adjustment is in the weft yarn count, which changes the fabric weight. The heaviest fabric uses the coarsest weft yarn, while the lightest fabric uses the finest weft yarn.

The fastness ratings are similar across all three fabrics, which means that changing the weight has not significantly improved or reduced rubbing and laundering fastness. This is important because fastness depends more on dyeing, washing and finishing conditions than on weight alone.

Knowledge Nugget

In denim, the blue character comes mainly from the warp, but the body of the fabric is strongly influenced by the weft. Therefore, two denim qualities can have a similar face appearance but different weight and handle because of the weft yarn.

Conclusion

The original table is small, but it contains a useful technical lesson. Denim weight is not an isolated property. It is connected with yarn count, fabric construction and finishing. In the given examples, all three fabrics have nearly the same EPI, PPI and warp count, while the weft count changes. This change in weft count explains the difference between heavier and lighter denim fabrics.

For a merchandiser, this type of specification is very valuable. It helps in understanding why a fabric feels heavier, why one denim quality may feel more rigid, and why fastness ratings must be checked even when the construction looks acceptable. A good denim evaluation should always combine measurable data with hand feel, shade behaviour, washing performance and final garment requirement.

Related Reading on Denim, Fabric Construction and Finishing

• Some Notes on Denim Washing
• Critical Process Parameters- Denim Manufacturing
• Manufacturing Process of Denim
• How to calculate the weight of Fabric
• Count, Construction and Width of common Cotton Fabrics

General Disclaimer

This article is intended for educational and practical understanding of textile and denim concepts. Actual fabric properties may vary depending on fibre quality, yarn type, spinning method, weaving conditions, dyeing process, finishing route, testing method and buyer specification. Readers should verify production decisions with mill technologists, testing laboratories, buyer standards and applicable textile testing methods before applying these values commercially.

Controlling Shade in Indigo Dyeing of Denim

If shade is getting:

Redder- Increase the conc. of Caustic , slightly decrease the conc. of Hydro
Redder, Duller- Increase the con. of hydro
Greener, Paler- decrease the con. of hydro
Greener, duller- Increase the con. of caustic
Bronzing- Increasing the con. of Hydro

Denim of Polyester Cotton Blend

In such denims, the polyester used in warp is kept low about 20-25%, because the blend is harder to dye than cotton . Polyester can be used in much higher percentage in filling. It has the advantage of being strong, durable and even in appearance.

Blending at draw frame

Blending at Draw Frame

This method is normally used for binary blends only. The required blend proportion is adjusted by the number of slivers of each component and the hank of respective slivers.

The fleece blending is done on the blending Drawframes specifically designed for this purpose. They are fed with 16-20 slivers at the back and therefore provide a much greater flexibility as regards the blend ratios.

Advantage

- Easier to obtain uniform blend ratio.
- During opening and carding, optimum settings fro each blend component can be used for better quality of output with less damage to the fibres. 

- Easy working.

Disadvantages

- Difficult to attain random arrangement of fibres in the yarn cross section.
- Additional drawing capacity needed.
- Separate opening lines needed for each component.

Blending of Combed Cotton Sliver and Polyester

Many Indian mills resort to this practice when the humidity control or conditions of machines is very poor.

Advantages
- Produces very intimate blend
- Trouble free running and high productivity at card.
- Less yarn imperfections due to better fibre individualisation because of reprocessing of the cotton component.
- Reduced number of d/f passages.
- Lower end breaks due to fewer slubs.
-better uniformity of dyeing due to more intimate blend.

Disadvantage
- Poor tenacity and evenness in blend yarn.
- High cotton nep content in blend due to reprocessing
- Need of additional b/r and card capacity
- Slightly higher waste in b/r and carding.

Optimum Blending Method of various Blends

1. For blends like P/V , blowroom blending is effective as they need similar b/r sequence.
2. For blending of manmade stack blending method is generally used.
3. The polyester /cotton or acrylic/cotton are generally blended at d/f because cotton component needs a severe opening and cleaning action
4. Where there is a problem of running 100% polyester on card, stack blending of polyester stock and combed cotton may be resorted to.
5. In case of v/c blend, they should be blended at the draw/frame as they need quite a different opening sequence.  

Blending at Blowroom

Blending at Blowroom: Methods, Advantages and Limitations

In cotton spinning, blending is one of the most important operations carried out at the blowroom stage. The purpose of blending is to mix different fibre components in the required proportion so that the final yarn has consistent quality, appearance, strength, and performance.

Blending may be required for several reasons: to mix cottons of different varieties, to combine natural and man-made fibres, to use recovered fibre waste in a controlled manner, or to maintain uniformity when fibres come from different bales or lots.

At the blowroom, blending is generally carried out by three main methods:

1. Feeder blending
2. Stack blending
3. Lap blending

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1. Feeder Blending

In feeder blending, different fibre components are fed into different hopper feeders. The feed from each hopper is adjusted according to the required blend ratio.

For example, if a blend of cotton and polyester is required, cotton may be fed through one hopper feeder and polyester through another. The delivery from each feeder is adjusted so that the desired percentage of each fibre is obtained in the final blend.

The amount of material taken from each bale for feeding these blenders should generally not exceed 2–3 kg. Taking small quantities from many bales helps in achieving better mixing and reduces variation between bales.

This method is generally employed when more than two components are required to be blended.

Practical Note:
Feeder blending is useful when the mill wants flexibility in changing blend ratios. However, the accuracy of the blend depends greatly on the correct setting and regular monitoring of the feeders.

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2. Stack Blending

In stack blending, the blend components from the bale or from bale breakers are first weighed. These pre-opened fibre components are then laid down in alternate layers to form a stack.

The stack is usually laid horizontally. During feeding, the material is withdrawn vertically. This vertical withdrawal helps in taking fibre from several layers at the same time, which improves mixing.

For example, if cotton, polyester, and recovered fibre are to be blended, they may be laid layer by layer in the required proportion. When the stack is cut or withdrawn vertically, material from all layers is taken together, producing a more mixed feed.

Technical Note:
Stack blending depends heavily on accurate weighing and careful layer formation. If the layers are not uniform, the final blend may show variation.

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Advantages of Feeder and Stack Blending

Both feeder blending and stack blending are widely used because they can provide a reasonably intimate and homogeneous blend when properly controlled.

• More intimate and homogeneous blending can be achieved.
• Only one opening line is generally needed.
• They provide simple control over the use of recovered fibre waste.
• They require minimum man-hours for blending when properly organized.

Disadvantages of Feeder and Stack Blending

However, these methods also have some limitations. The blend quality depends on the accuracy of feeding, weighing, and operator control.

• It may be difficult to attain a perfectly uniform blend ratio.
• They demand greater skill on the part of the operator.
• They can be labour-intensive and somewhat slow, especially in manual systems.

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3. Lap Blending

In lap blending, laps of the component fibres are prepared separately, usually at the breaker scutcher. Generally, three to four laps are produced and then fed together to the finisher scutcher in the desired ratio.

Each lap represents a particular fibre component or blend component. By feeding these laps together, a more controlled blend can be obtained. Since the lap weights can be measured and controlled, lap blending provides better control over the blend ratio.

This method was more common in older blowroom lines where scutchers and lap-forming machines were used. In modern blowroom systems, chute feed systems have largely replaced lap-forming systems, but the principle remains important for understanding traditional blowroom blending.

Advantages of Lap Blending

• It ensures good blend homogeneity.
• It is easy to work once the system is properly set.
• It provides good control over the use of recovered fibre waste.
• A uniform blend ratio can be achieved.

Disadvantages of Lap Blending

• The opening line has to be modified to provide both breaker and finisher scutchers.
• Proper control over lap weights is essential.
• Additional machinery and handling may be required.
• If lap weights vary, the blend ratio may also vary.

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Comparison of Blending Methods at Blowroom

Method	Basic Principle	Main Advantage	Main Limitation
Feeder Blending	Different fibres are fed through separate hopper feeders in the required ratio.	Useful for blending more than two components.	Uniformity depends on feeder setting and control.
Stack Blending	Fibres are weighed, laid in alternate layers, and withdrawn vertically.	Simple and suitable for pre-opened fibres.	Requires careful weighing and skilled handling.
Lap Blending	Laps of different fibre components are fed together to the finisher scutcher.	Provides better control over blend ratio.	Requires control of lap weights and suitable machinery.

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Importance of Proper Blending

Proper blending at the blowroom stage has a direct effect on the quality of yarn. If the blending is poor, the yarn may show variation in strength, colour, dye uptake, evenness, and appearance.

In blended yarns such as polyester-cotton, viscose-cotton, or cotton mixed with recovered fibre, improper blending may lead to streakiness, shade variation after dyeing, and inconsistent performance during spinning.

Therefore, the blowroom blending method must be selected according to the type of fibres, number of components, required blend accuracy, machinery available, and the quality level expected in the final yarn.

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Conclusion

Blending at the blowroom is not merely a mechanical mixing operation. It is a quality-control operation that determines the uniformity of the material right from the beginning of the spinning process.

Feeder blending and stack blending are simpler methods and are suitable where flexibility and basic control are required. Lap blending, on the other hand, offers better control over blend ratio but needs proper machinery and careful control of lap weights.

A good blowroom blending system should achieve three things: the correct blend ratio, uniform distribution of fibres, and minimum variation from bale to bale and batch to batch.

Blending-2

How to select Blend Constituents


Selection of Blend Constituents depends upon the following factors:

1. Type of Fibre
- Depending upon the end use of the fabric, blend constituents are chosen.

- For example, it is well known hat a polyester-cotton yarn looks fuller as compared to the lean look of polyester-viscose yarn.

- Therefore for light constructions like shirtings, polyester-cotton blend is used.

- However polyester-viscose blend is preferred for medium and heavy construcitons such as suitings.

2. Compatibility of blend fibres

Compatibility must be there in terms of the following properties:

a. Length and Denier of Fibres:

- As a general rule, these two fibre properties should be nearly the same for all the constituents.
- For example in a viscose rayon cotton blend, the rayon staple of 1.5 denier and 29-32 mm length is generally used since the cotton component used has a denier of around 1.5 and a length of 28mm.

b. Extensibility

- A large difference in the breaking elongation of the fibres in a blend adversly affects the yarn tenacity.

c. Density
- The blend fibres should prefereably have the same density. Any large differences on this account will lead to selctive separation while conveying the blended stock through ducts under the influence of air suction in the blow rooms.

d. Dispersion Properties
- This property describes the ability of an individual fibre to separate from its group and disperse thoroughly within the fibre matrix of the blend to produce an intimate and homogeneous blend.

e. Drafting Properties
- Some fibres like viscose are outstanding it terms of draftability. These fibres, when blended with other fibres act as good carriers to obviate the trouble relating to drafting.

f. Dyeing Properties
- In case the blend yarn or fabric is to be dyed subsequently, due consideration should be given to the dyeing properties of individual fibre components.

CHARACTERISTICS DESIRED IN A BLEND YARN

A. The constituent fibres should be arranged at random in the yarn cross section.

B. The ratio between the blended fibres should be uniform at any cross section of the yarn.

C. There should not be any long-term or short-term irregularity in blend ratio of blended fibres.

Blending-1

Blending-1

Neither natural or manmade fibres are optimally suited to certain fields of use, but a blend of these two fibres types can give the required characteristics.

Objectives:

1. Improvement in Functional Properties

A 100% single fibre yarn cannot impart all the desired properties to a fabric.

For example 100% viscose rayon suffer from low tensile strength, poor crease resistance and low abrasion resistance.

Similarly 100% polyester fabrics are not desirable as they are prone to static accumulation, hole melting and pilling. They are moisture resistant, difficult and expensive to dye and have a poor hand.

These negative attributes of polyester and viscose can be reasonably neutralised by addition of a certain percentage of each fibre.

2. Improved Process performance

Some fibres like polyester at times are quite troublesome to work in 100% form especially at cards. Addition of fibres like cotton or viscose rayon in the previous process has been seen to facilitate the smooth carding of such fibres.

The blending of manmades which are longer and finer to cotton which is shorter influences the spinnablility as well as productivity.

3. Economy

The price of manmades is much more stable than that of natural fibres like cotton. Price stability can enable the mills to pursue optimisation of their fibre purchase programme.

Blending could also be used for reducing the mixing cost. For example, a fibre like viscose can be blended with cotton for producing specific yarns with reduced raw material costs.

4. Fancy Effect

Fibres with a variety of colour mixture or shades can be produced by blending different dyed fibres at the blowroom, drawframe or roving stage.

5. Aesthetics

The aesthetics of a fabric can be developed by selecting specific blend components and their properties.